3600 Mechanical Unit Injector (MUI) to 3600 Electronic Unit Injector (EUI) Upgrade{1000, 1250} Caterpillar

Engine:

3606 (S/N: 8RB1-UP)

3608 (S/N: 6MC1-UP)

3612 (S/N: 9RC1-UP)

3616 (S/N: 1PD497-UP)

Introduction

Do not perform any procedure in this Special Instruction until you read this information and you understand this information.

This Special Instruction provides the following information for 3600 Engines:

• Requirements for the electrical system

• Requirements for the starting system

• References for electrical schematics

• Required electronic service tools

• Cylinder head installation

• Modifications for the cylinder head

• Fuel injector installation

• Components of the Customer Interface Panel (CIP)

• Specifications for the customer connector

• Wiring connections and the corresponding functions that are available to the customer

• Initial start-up procedure

ReferenceInformation from the following sources will be needed for this Special Instruction:

• Special Instruction, REHS3402, "Modifications for the Flywheel Housing on 3616 Engines to Use Electronic Unit Injectors (EUI)"

• Operation and Maintenance Manual, SEBU7876, "C280 Marine, Marine Auxiliary, and Petroleum Engines"

• Operation and Maintenance Manual, SEBU6965, "3600 Distillate Fuel Engines"

• Operation and Maintenance Manual, SEBU7632, "Monitors For 3600 Diesel Monitoring Systems"

• Systems Operation/Testing and Adjusting, SENR3599, "3606 and 3608 Engines"

• Systems Operation/Testing and Adjusting, SENR3593, "3612 and 3616 Engines"

• Disassembly and Assembly, SENR3600, "3606 and 3608 Engines"

• Disassembly and Assembly, SENR3594, "3612 and 3616 Engines"

• Troubleshooting, RENR2491, "3606, 3608, 3612 and 3616 Engines Generator Monitoring System"

• Troubleshooting, RENR5084, "C280 Marine Propulsion Engines"

• Troubleshooting, KENR5434, "C280 Marine Auxiliary Engines"

• Electrical Schematic, RENR5086, "C280-6 and C280-8 Marine Propulsion Engine Electrical System"

• Electrical Schematic, RENR5087, "C280-12 and C280-16 Marine Propulsion Engine Electrical System"

Note: Flywheel housing identification is important in determining the conversion processes needed for the EUI update. Be sure to identify correctly the installed flywheel housing before performing any of the following procedures. Special Instruction, REHS3402, "Modifications for the Flywheel Housing on 3616 Engines to Use Electronic Unit Injectors (EUI)" is not performed with the following :

• Vee configuration with 284-5208 Rear Housing installed with the 288-4407 Cover installed on the side.

• Vee configuration that can use the 240-9740 Rear Housing Cover Gp .

Engine Information Plate

Illustration 1	g01053234
(1) Engine information plate

The engine information plate is located between the last two crankcase covers on the right side of the engine. The engine information plate must be modified in order to show that the upgrade has been completed.

A request must be submitted to the Applications Support Center to obtain a new engine identification plate. The request must state that the new identification plate is for the Mechanical Unit Injector (MUI) to Electronic Unit Injector (EUI) conversion. The request must include the following information.

• An e-mail address

• A phone number

• The serial number of the engine

The new plate will include information on the timing devices for the engine and the software part numbers for the engine.

Removal and Installation

The new engine identification plate is installed over the existing plate. Ensure that the existing plate is clean. Ensure that the existing plate is free of oil.

Upgrades for the Fuel System

Replace Fuel Filters

Remove Existing Fuel Filters

Table 1

Required Tools
Tool	Part Number	Part Description	Qty
A	7V-0198	Hose	1
B	4F-4879	Bolt	2
C	4C-6173	Fuel Drain Tray	1
D	5N-5566	Hose	1
E	1U-9823	Filter Scoop	1

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates.

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NOTICE
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Shut off the fuel supply to the engine.

Note: Tool (C) is mounted on the lower fuel filter housing. This tray allows fuel to drain.

2. Install Tool (C), Tool (B), Tool (A), and Tool (D). Drain the fuel from each fuel filter bank by opening the drain valves.

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Illustration 2	g00617652

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Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened.

3. Remove covers (1) .

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Illustration 3	g00617656

4. Pull out wire racks (3) and remove one fuel filter element (2) at a time from each housing. When the filters are being installed, always use new filters.

5. Use Tool (E) in order to handle the fuel filter elements for disposal.

Install the 1R-0766 Fuel Filter Element As

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NOTICE
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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Illustration 4	g00617656

1. Put new filters in wire racks (3) and install the filters one at a time.

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Illustration 5	g00617652

2. Install covers (1) .

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Illustration 6	g00617646

3. Remove Tool (C), Tool (B), Tool (A), and Tool (D). Close the drain valves.

Upgrade for the Bypass Valve on the Fuel Transfer Pump

Modify the Valve

Note: This procedure may be performed without disassembling the fuel transfer pump.

Illustration 7	g01268600
(1) Fuel transfer pump (2) Bypass valve for the fuel transfer pump

Illustration 8	g01268699
Bypass valve for the fuel transfer pump (3) Cap (4) Locknut (5) Adjustment screw (6) Plug (7) Spring (8) Bypass valve for the fuel transfer pump (9) Guide

1. Remove cap (3), plug (6), guide (9), and spring (7) from housing (8) .

2. Replace spring (7) with 238-0939 Spring .

   Install the new 238-0939 Spring .

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Illustration 9	g01268732

3. Loosen locknut (4). Adjust screw (5) until dimension (X) is 7 mm (0.275 inch). Tighten locknut (4) and then recheck dimension (X) .

4. Install cap (3) and plug (6) onto housing (8) .

Fuel Pressure Regulator

1. Turn off the fuel system to the engine.

2. Drain the fuel system. Reference Special Publication, NENG2500, "Dealer Service Tool Catalog" for the tools and supplies that are needed in order to collect fluids and contain fluids on Caterpillar products.

3. In order to relieve the tension on the pressure regulating spring, turn square head setscrew (9) counterclockwise. Remove bolts (8) and washers (7). Remove plate (6) from valve body (1) .

4. Remove the spring and the retainer from the body of the fuel pressure regulator.

5. In order to upgrade the fuel pressure regulator, replace spring (2) and spacer (3). Refer to Illustration 10.

6. Apply 1P-0808 Multipurpose Grease to the threads of square head setscrew (9). Also apply the grease to valve body (1) after retainer (5) and O-ring seal (4) are installed.

Illustration 10	g01631394
Fuel pressure regulator (1) Valve body (2) 330-9050 Spring (3) 331-3971 Spacer (4) 3P-1156 O-Ring Seal (5) 7W-7727 Retainer (6) 7W-7726 Plate (7) 5P-0537 Hard Washer (8) 4F-7957 Bolt (9) 4B-3611 Square Head Setscrew (10) 9S-8752 Full Nut (B) Height of the square head setscrew

(B) Height of the square head setscrew

Adjust the height of the square head setscrew in order to provide the following fuel pressure at rated load and at rated speed:

Fuel pressure ... 820 ± 20 kPa (119 ± 3 psi)

Update the Engine Timing Group for In-line Engines

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Be sure that the engine cannot be started while service work is being done. This is very important when the engine is equipped with an Automatic Start-Stop System. On engines equipped with an air starting system, close the air supply valve that supplies air to the starter motor before service work is begun.

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Improper lift rigging can allow unit to tumble causing injury and damage.

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NOTICE
When it is necessary to remove a component at an angle, remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less than 90 degrees. Eyebolts and brackets should never be bent and should only be loaded in tension.

1. Remove the 4P-7003 Camshaft Drive Gear Cover Gp

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Illustration 11	g01268729
112-5051 Governor Fastener (1) Clamps (2) Rod (3) Actuator assembly (4) Control rod housing

2. Remove the 112-5051 Governor Fastener .

   1. Remove clamps (1) and rod (2). The clamps and rod will not be reinstalled.

3. Remove actuator (3) .

   1. Disconnect the electrical connectors from the actuator.

   2. Remove the bolts that secure the actuator to the governor drive.

   3. Remove the actuator.

4. Remove housing (4) .

5. Remove the fuel injection control linkage.

   Refer to the Disassembly and Assembly manual for more information.

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Illustration 12	g01268723
Governor drive group (5) Bolts (6) Bevel gear (7) Camshaft

6. Remove the 2W-1242 Governor Drive Group .

   1. Remove bolts (5) .

   2. Remove the governor drive.

   3. Remove the governor drive housing.

      Note: Leave bevel gear (6) mounted on camshaft (7) .

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Illustration 13	g01287903
237-5389 Camshaft Cover Gp (8) 253-8893 Housing (9) 206-7469 Cover

7. Install housing (8) .

8. Install the two speed sensors (11) and (13) .

   191-8305 Speed Sensor Gp

   Clearance between tip of the sensor and the wheel ... 0.750 mm to 2.000 mm (0.0295 inch to 0.0787 inch)

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Illustration 14	g03089597
Standard rotation (10) Speed/timing wheel (11) Primary 191-8305 Speed Sensor Gp (12) Extra tooth (13) Secondary 191-8305 Speed Sensor Gp (14) 1D-4569 Bolts

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Illustration 15	g03089601
Reverse rotation (10) Speed/timing wheel (11) Primary 191-8305 Speed Sensor Gp (12) Extra tooth (13) Secondary 191-8305 Speed Sensor Gp (14) 1D-4569 Bolts

9. Install the 213-6456 Timing and Speed Drive .

   1. Ensure that the engine is in time by inserting the timing pin into the camshaft.

   2. Install the 196-6043 Spacer and the 154-2709 Wheel on the camshaft drive gear.

      Ensure that the tooth trailing the extra tooth (12) on speed/timing wheel (10) is centered with the primary speed sensor (13). Install 5P-8245 Hard Washers on bolts (14). Do not tighten bolts (14) .

      Note: Note the position of extra tooth (12) in relation to primary speed sensor (13) .

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Illustration 16	g03124519
Standard rotation (10) Speed/timing wheel (11) Primary speed sensor (12) Extra tooth

10. Adjust the 154-2709 Wheel .

    1. Rotate speed/timing wheel (10) in the direction of the camshaft rotation.

    2. Align the tooth trailing the extra tooth (12) with the center of primary speed sensor (134) .

       Refer to Illustration 16.

    3. Torque bolts (14) to 120 N·m (90 lb ft).

    4. Recheck the alignment of the tooth trailing the extra tooth (12) and primary speed sensor (11) .

11. Install the 248-6764 Camshaft Cover Gp .

    The 248-6764 Camshaft Cover Gp replaces the 112-5051 Governor Fastener and the 138-4139 Governor Actuator As .

12. Install the 240-9736 Cylinder Block Cover Gp .

    1. Install the 4B-3140 Covers . Use 1W-1960 Gaskets , 3V-3308 Hard Washers , and 0S-1594 Bolts .

       The 4B-3140 Cover replaces the opening in the block for the fuel control rod.

    2. Install the 7E-5420 Cover . Use 1W-3557 Gasket , 3V-3308 Hard Washers , and 3B-1915 Bolts .

       The 7E-5420 Cover replaces the opening in the block for the governor actuator assembly.

13. Install the 206-7469 Cover .

Update the Engine Timing Group for Vee Engines With the 284-5208 Rear Housing and 288-4407 Cover

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Be sure that the engine cannot be started while service work is being done. This is very important when the engine is equipped with an Automatic Start-Stop System. On engines equipped with an air starting system, close the air supply valve that supplies air to the starter motor before service work is begun.

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Improper lift rigging can allow unit to tumble causing injury and damage.

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NOTICE
When it is necessary to remove a component at an angle, remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less than 90 degrees. Eyebolts and brackets should never be bent and should only be loaded in tension.

Table 2 contains the parts needed for installation of the engine timing group. Use the following procedure if the engine has a 284-5208 Rear Housing already installed.

Table 2

Item	Qty	Part Number	Part Description
5	1	295-3041	Adapter
6	1	5F-0149	O-Ring Seal
7	4	0S-1617	Bolt
8	6	9M-1974	Hard Washer
9	2	2H-3755	Bolt
10	1	293-2879	Speed Sensor Gp
11	1	293-2878	Speed Sensor Gp
12	2	117-1385	O-Ring Seal

Illustration 17	g03360632
(1) 288-4407 Cover (2) 5F-0149 O-Ring Seal (3) 2B-2695 Bolt (4) 9M-1974 Hard Washer

1. Remove bolts (3) with hard washers (4). Take off cover (1) with o-ring seal (2) that should be on the inside of the cover.

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Illustration 18	g03360918
(5) 295-3041 Adapter (6) 5F-0149 O-Ring Seal (7) 0S-1617 Bolt (8) 9M-1974 Hard Washer

2. Install adapter (5) with o-ring seal (6) installed on the back of the adapter. Use four bolts (7) with four hard washers (8) to install the adaptor on the side of the flywheel housing.

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Illustration 19	g03360924
(8) 9M-1974 Hard Washer (9) 2H-3755 Bolt (10) 293-2879 Speed Sensor Gp (11) 293-2878 Speed Sensor Gp (12) 117-1385 O-Ring Seal

3. Install speed sensor group (10) with o-ring seal (12) in the top hole of the adaptor using bolt (9) and hard washer (8). Install speed sensor group (11) with o-ring seal (12) in the bottom hole of the adaptor using bolt (9) and hard washer (8) .

Update the Engine Timing Group for Vee Engines Using 240-9740 Rear Housing Cover Gp

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Be sure that the engine cannot be started while service work is being done. This is very important when the engine is equipped with an Automatic Start-Stop System. On engines equipped with an air starting system, close the air supply valve that supplies air to the starter motor before service work is begun.

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Improper lift rigging can allow unit to tumble causing injury and damage.

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NOTICE
When it is necessary to remove a component at an angle, remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less than 90 degrees. Eyebolts and brackets should never be bent and should only be loaded in tension.

Use the following procedure in order to update the engine timing group for 12 cylinder engines with the 240-9740 Rear Housing Cover Gp . Table 3 contains the parts need for installation of the engine timing group.

Table 3

Item	Qty	Part Number	Part Description
14	1	253-8894	Housing
15	1	159-7187	Cover
16	1	154-2709	Wheel
17	1	191-8305	Speed Sensor Gp
18	4	2A-1531	Bolt
21	1	191-8305	Speed Sensor Gp
22	1	154-8716	Spacer
23	4	5P-1076	Hard Washer
24	1	4B-3140	Cover
25	1	1W-1960	Gasket
26	2	0S-1594	Bolt
27	10	3V-3308	Hard Washer
28	1	6V-6050	Seal
29	8	3B-1915	Bolt

1. Remove the 7E-1291 Camshaft Drive Gear Cover Gp .

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Illustration 20	g01268616
120-4508 Governor Fastener (1) Clamps (2) Rod (3) Actuator assembly (4) Control rod housing

2. Remove the 120-4508 Governor Fastener .

   1. Remove clamps (1) and rod (2). The clamps and rod will not be reinstalled.

3. Remove actuator (3) .

   1. Disconnect the electrical connections for the actuator.

   2. Remove the bolts that secure the actuator to the governor drive.

   3. Remove the actuator.

4. Remove housing (4) .

5. Remove the fuel injection control linkage.

   Refer to the Disassembly and Assembly manual for more information.

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Illustration 21	g01268741

6. Remove the 4P-9212 Governor Drive Group .

   1. Remove bolts (11) .

   2. Remove ten bolts (6). Remove cover (8) .

   3. Fasten a hoist to housing assembly (5). Remove bolts (10) that hold the housing assembly to the rear housing. Install two 3/8 - 16 NC forcing screws in housing assembly (5). Tighten the forcing screws evenly and separate the housing assembly from the rear housing. Remove housing assembly (5). The weight of housing assembly (5) is approximately 25 kg (55 lb).

   4. Remove the O-ring seal from housing assembly (5) .
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   Illustration 22	g01268644

   5. Remove four bolts (12). Remove adapter (13) .

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Illustration 23	g01288013
240-9740 Rear Housing Cover Gp (14) 253-8894 Housing (15) 159-7187 Cover

7. Install housing (14) .

8. Install the two speed sensors (17) and (21) .

   191-8305 Speed Sensor Gp

   Clearance between tip of the sensor and the wheel ... 0.750 mm to 2.000 mm (0.0295 inch to 0.0787 inch)

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Illustration 24	g03360372
Standard rotation (16) 154-2709 Wheel (17) Secondary 191-8305 Speed Sensor Gp (18) 2A-1531 Bolts (19) Extra tooth (20) Tooth after the extra tooth (21) Primary 191-8305 Speed Sensor Gp (23) 5P-1076 Hard Washer

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Illustration 25	g03360368
Reverse rotation (16) 154-2709 Wheel (17) Secondary 191-8305 Speed Sensor Gp (18) 2A-1531 Bolts (19) Extra tooth (20) Tooth after the extra tooth (21) Primary 191-8305 Speed Sensor Gp (22) 154-8716 Spacer (23) 5P-1076 Hard Washer

9. Install the 213-6456 Timing and Speed Drive .

   1. Ensure that the engine is in time by inserting the timing pin into the camshaft.

   2. Install the spacer (22) and wheel (16) on the camshaft drive gear.

      Note: Note the position of extra tooth (19) in relation to primary speed sensor (21) .

   3. Ensure that the tooth after the extra tooth (20) on wheel (16) is close to primary speed/timing sensor (21). Install hard washers (23) on bolts (18). Do not tighten bolts (18) .

10. Adjust the wheel (16) .
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    Illustration 26	g03124737
    Reverse rotation (16) 154-2709 Wheel (21) 191-8305 Speed Sensor Gp (20) Extra tooth

    1. Rotate speed/timing wheel (16) in the direction of camshaft rotation.

    2. Align the first tooth after the extra tooth (20) with the center of primary speed/timing sensor (21) .

       Refer to Illustration 26.

    3. Torque bolts (18) to 120 N·m (90 lb ft).

    4. Recheck the alignment of first tooth after the extra tooth (20) and primary speed/timing sensor (21) .

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Illustration 27	g03360287
(24) 4B-3140 Cover (25) 1W-1960 Gasket (26) 0S-1594 Bolt (27) 3V-3308 Hard Washer

11. Install the cover (24) using gasket (25), two hard washers (27), and two bolts (26) .

    The cover (24) replaces the opening in the block for the fuel control rod.

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Illustration 28	g03360333
(15) 159-7187 Cover (28) 6V-6050 Seal (27) 3V-3308 Hard Washer (29) 3B-1915 Bolt

12. Install the cover (15) using seal (28), eight bolts (29), and eight hard washers (27) .

Cylinder Heads

The cylinder head must be upgraded in order to use the new injector. Choose one of the following options.

• New cylinder heads

• Remanufactured cylinder heads

• Modifying the existing cylinder heads

Using New Engine Cylinder Heads to Upgrade the Engine

Table 4

Engine Cylinder Head Assembly Part Numbers
252-5626 (Cyclic)	296-6837 (Non-cyclic)

1. Remove the old cylinder head.

   Refer to the Disassembly and Assembly manual.

Note: When the cylinder head is disassembled, keep the bridges and the respective valves together.

2. Disassemble the old head.

3. Inspect the 1W-8444 Shaft Supports .

   Replace the 1W-8444 Shaft Supports if the shaft supports are change level 06 or below. The shaft supports must be change level 07 or above.

4. Inspect the existing parts for the engine cylinder head. If the parts are in good condition, the parts can be reused.

5. Assemble the new cylinder head.

6. Install the new cylinder head.

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Illustration 29	g03361450
EUI injector (1) 276-1354 Spacer Ring (2) 269-4659 Seal (3) 425-2519 O-Ring Seal (4) 061-9455 O-Ring Seal

7. Install the seals onto the 288-2403 Fuel Injector Gp .

   Note: Lubricate spacer (1), seal (2), o-ring seal (3), and o-ring seal (4) with engine oil or diesel fuel prior to installation on the fuel injector.

   1. Install spacer (1) onto the fuel injector.

   2. Install seal (2) onto the fuel injector.

   3. Install O-Ring (4) onto the fuel injector.

8. Install the 288-2403 Fuel Injector Gp using the 198-8832 Injector Clamp , the 7S-3224 Bolt and a 198-8833 Washer .

   7S-3224 Bolt

   Torque ... 215 ± 40 N·m (160 ± 30 lb ft)

9. Install the 6I-2491 Bridge Assemblies .

10. Install the 128-5682 Rocker Arms .

11. Install the 198-8839 Rocker Arm Base .

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Illustration 30	g03360992
(5) 9X-0352 Receptacle As (6) 6J-2245 O-Ring Seal (7) 0S-1615 Bolt (8) 5P-0537 Hard Washer

12. Install receptacle assembly (5) with o-ring seal (6) in the side of the rocker arm base. Tighten down the receptacle assembly with bolt (7) and washer (8). Apply Loctite item number 1329837 to the bolt threads and torque bolt (7) to 12 ± 3 N·m (106 ± 27 lb in)

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Illustration 31	g03361009
(9) Tabs (10) Metal tag (11) Location for the 9X-0352 Receptacle As

13. Connect the injector wiring harness to the 9X-0352 Receptacle As .

    Ensure that the wiring harness for the injector is correctly routed through tabs (9) of the 198-8839 Rocker Arm Base .

    Note: Metal tag (10) must be positioned between the fuel injector solenoid and the first tab of the rocker arm base. The information on the tag must be visible.

14. Install the 7E-0733 Valve Mechanism Cover after the valves and valve bridges have been adjusted.

Using Remanufactured Engine Cylinder Heads to Upgrade the Engine

Table 5

Part Numbers for Remanufactured Cylinder Heads
10R-4829 (Cyclic)	10R-5980 (Non-cyclic)

The remanufactured engine cylinder head has the correct mounting hole size for the injector.

1. Remove the old cylinder head.

   Refer to the Disassembly and Assembly manual.

2. Disassemble the old head.

3. Install the 10R-4829 Cylinder Head Gp .

4. Inspect the 1W-8444 Shaft Supports .

   Replace the 1W-8444 Shaft Supports if the shaft supports are change level 06 or below. The shaft supports must be change level 07 or above.

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Illustration 32	g03361450
EUI injector (1) 276-1354 Spacer Ring (2) 269-4659 Seal (3) 425-2519 O-Ring Seal (4) 061-9455 O-Ring Seal

5. Install the seals onto the 288-2403 Fuel Injector Gp .

   Note: Lubricate spacer (1), seal (2), and O-Ring (4) with engine oil or diesel fuel prior to installation on the fuel injector.

   1. Install spacer (1) onto the fuel injector.

   2. Install seal (2) onto the fuel injector.

   3. Install o-ring seal (3) onto the fuel injector.

   4. Install o-ring seal (4) onto the fuel injector.

6. Install the 288-2403 Fuel Injector Gp using the 198-8832 Injector Clamp , the 7S-3224 Bolt and a 198-8833 Washer .

   7S-3224 Bolt

   Torque ... 215 ± 40 N·m (160 ± 30 lb ft)

7. Install the 6I-2491 Bridge Assemblies .

8. Install the 128-5682 Rocker Arms .

9. Install the 198-8839 Rocker Arm Base .

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Illustration 33	g01268735
(5) Tabs (6) Metal tag (7) Location for the 9X-0352 Receptacle As

10. Connect the injector wiring harness to the 9X-0352 Receptacle As .

    Ensure that the wiring harness for the injector is correctly routed through tabs (5) of the 198-8839 Rocker Arm Base .

    Mount the 9X-0352 Receptacle As in the rocker arm base.

    Note: Metal tag (6) must be positioned between the fuel injector solenoid and the first tab of the rocker arm base. Make sure that the information on the tag is visible.

11. Install the 7E-0733 Valve Mechanism Cover after the valves and valve bridges have been adjusted.

Upgrade the Engine Cylinder Heads by Modifying Existing Cylinder Heads

Table 6

Required Tools
Tools	Part Number	Part Description
(A)		6 mm (0.25 inch) round stock that is 76 mm (3 inch) long
(B)	4C-4999	Taper Tap
(C)		13.8 mm drill bit
(D)	4C-5026	Tap Wrench
(E)	4C-4981	Bottom Tap
(F)		Chamfer cutting tool DB 26-90 degree
(G)	1U-7262	Telescoping Magnet
(H)		Magnetic Drill
(I)		Plate
Additional Required Tools
Wet/dry shop vacuum
Tape

Illustration 34	g01268677
Machining tools for the cylinder head

Illustration 35	g01268719
Typical example of magnetic drill

Refer to Table 7, Illustrations 36,37 38, and 39 in order to fabricate plate (I). The plate is fabricated from steel.

Table 7

Plate
Callout	Description
Front View
1	Steel tube
2	Steel plate
3	Steel plate
AA	Fillet weld 3 mm (0.1181 inch) skip weld 5 places
BB	Dimension 5 mm (0.1969 inch)
CC	Dimension 70 mm (2.7559 inch)
DD	Dimension 135 mm (5.3150 inch)
EE	Radius 42.9 mm (1.6890 inch)
FF	Dimension 185 mm (7.2835 inch)
GG	Radius 39.1 mm (1.5394 inch)
HH	Dimension 120 mm (4.7244 inch)
II	Dimension 8 mm (0.3150 inch)
JJ	Radius 23 mm (0.9055 inch)
KK	Diameter 20.5 mm (0.8071 inch)
LL	Dimension 100 mm (3.9370 inch)
MM	Radius 30 mm (1.1811 inch)
NN	Dimension 23 mm (0.9055 inch)
OO	Dimension 163 mm (6.4173 inch)
Rear View
CC	Dimension 70 mm (2.7559 inch)
PP	Diameter 25.4 mm (1.0000 inch)
QQ	Dimension 125 mm (4.9213 inch)
RR	Dimension 99 mm (3.8976 inch)
SS	Diameter 12.7 mm (0.5000 inch) depth 10 mm (0.3937 inch) bottom must be flat
TT	Dimension 30 mm (1.1811 inch)
UU	Dimension 120 mm (4.7244 inch)
VV	Dimension 20 mm (0.7874 inch)
Side View
WW	Dimension 50.7 mm (1.9961 inch)
XX	Butt weld both sides 1.5 mm (0.0591 inch) 2 places
YY	Dimension 12.7 mm (0.5000 inch)

Illustration 36	g01404858
Front view

Illustration 37	g01404859
Rear view

Illustration 38	g01404860
Side view

Illustration 39	g01404861
Pictorial view

The standard 3600 cylinder head must be modified in order to accept the 235-3336 Fuel Injector Gp .

Table 8

Fuel Injector Parts
Standard Mechanical Unit Injector (MUI) Cylinder Heads		EUI Cylinder Heads
7C-1903	Fuel Injection Pump Gp	288-2403	Fuel Injector Gp
1W-0019	Injector Clamp	198-8832	Injector Clamp
150-4810	Studs	7S-3224	Bolt
Not Applicable		198-8833	Washer

Before any machining work is performed, the cylinder head must be protected from the debris that is generated by the machining process. Plate (1) covers the opening in the cylinder head casting for the camshaft. Plate (1) also covers the injector bore. The plate is installed by using the 6V-6869 Bolts that are used for the support assemblies. 19 mm (0.75 inch) washers are used as spacers for the plate.

A wet/dry shop vacuum must be used to capture machining debris as the head is machined. Tool (G) is used to clean debris from the machined hole.

Machining Procedure for the Engine Cylinder Head

The following procedure may be performed while the engine cylinder head is installed on the engine. The following procedure may also be performed while the engine cylinder head is removed from the engine. Ensure that all openings in the engine are covered or plugged.

1. Disassemble the following parts.
   • Rocker arms

   • Support assembly

   • Pushrods

   • Valve bridges

   • Fuel injector

   • Hold down studs for the fuel injector

   Refer to the Disassembly and Assembly manual for more information.

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Illustration 40	g01268738
(I) Plate

2. Install plate (I) .

   1. Place plate (I) onto the cylinder head.

   2. Use two 6V-6869 Bolts to secure the plate to the cylinder head.

      4B-4283 Washers may be used as spacers for the bolts.

3. Ensure that all of the openings in the cylinder head have been covered and/or plugged.

   Ensure that the valve springs are covered and/or protected.

4. Measure 41 mm (1.61 inch) from the tip of tools (B), (C), and (E) .

   Use the tape to mark the tools at 41 mm (1.61 inch).

5. Place magnetic drill (H) onto plate (I) .

6. Install tool (A) into the chuck of the magnetic drill.

   Leave 63 mm (2.5 inch) of tool (A) exposed.

   Note: Do not move the switch for the base of the magnetic drill to the ON position.

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Illustration 41	g01268705
(7) Hole

7. Lower the chuck of the magnetic drill until tool (A) is centered at the bottom of hole (7) .

8. Center tool (A) in hole (7), turn the magnetic drill to the ON position to keep the drill in place while the hole is machined.

9. Raise the chuck of the magnetic drill and remove tool (A) from the chuck of the magnetic drill.

10. Install tool (C) into the chuck of the magnetic drill.

11. Drill hole (7) to a depth of 41 mm (1.61 inch).

12. Use the shop vacuum and Tool (G) to remove any machining debris from the head casting and from the machined hole.

13. Using tool (B) and tool (D), tap the machined hole.

14. Repeat Step 12.

15. Use tool (E) and tool (D) in order to clean the threads of the machined hole.

16. Remove tool (C) from the chuck of the magnetic drill. Install tool (F) into the chuck of the magnetic drill.

17. Use tool (F) in order to chamfer the machined hole.

18. Turn the switch for the base of the magnetic drill to the OFF position. Remove the magnetic drill.

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Illustration 42	g02170275
Location of the part number.

19. If, upgrading the cylinder heads for IMO II inspection. The upgraded cylinder head must be one of the following part numbers:
    • 252-5415 Cylinder Head

    • 252-5580 Cylinder Head

    • 252-5613 Cylinder Head

    If you have one of the cylinder heads that are listed above, continue to 20.

    If you do not have one of the cylinder heads that are listed above, the cylinder head cannot be upgraded for IMO II. Continue to Step 21.

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Illustration 43	g02170279
Converted part number

20. Use a grinder to smooth a flat area next to the part number on the cylinder head. Mark the area with the appropriate stamps in order to identify the new part number of the converted cylinder head.

    Stamp the smoothed area on the cylinder head with "CONVERTED TO 252-5625".

21. Repeat Step 12.

22. Ensure that all of the engine cylinder head and the valve springs are free of machining debris.

23. Remove plate (I) from the cylinder head.

24. Remove any covers or plugs that were installed onto the cylinder head.

25. Refer to ""Using Remanufactured Engine Cylinder Heads to Upgrade the Engine" " for information on assembling and installing the cylinder head.

Finding the Top Center Position for the No. 1 Piston

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Illustration 44	g00311103
Timing pin location (1) Manual barring group (2) Storage position for timing pin

1. Remove the crankshaft timing pin from the timing pin storage position (2). The timing pin storage position is located below manual barring group (1) on the right side of the rear housing.

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Illustration 45	g00311105
Installation of crankshaft timing pin (3) Bracket on flywheel for timing (4) Mounting bracket for timing pin (5) Crankshaft timing pin

2. Prelube the engine. Use the electrically driven manual barring group in order to turn the engine flywheel in the direction of normal engine rotation. Turn the engine flywheel in the direction of normal engine rotation until crankshaft timing pin (5) can be installed through bracket (4). Then, install crankshaft timing pin (5) so that the pin is engaged in bracket (3) .

   Note: Prelube the engine before you rotate the crankshaft in order to perform service work. Rotating the crankshaft before prelube may damage the crankshaft bearings if the mating surface is dry.

   Note: The flywheel must be turned in the opposite direction of rotation, if the flywheel was turned past the timing hole. Turn the flywheel opposite the direction of normal rotation for approximately 20 degrees. Then, turn the flywheel in the direction of normal engine rotation until the timing pin can be installed in the flywheel bracket for timing. The procedure ensures that the play is removed from the timing gears.

3. Remove the valve cover from the No. 1 cylinder head.

4. The valves for the No. 1 cylinder are fully closed if No. 1 piston is on the compression stroke. On the compression stroke the rocker arms should move by hand. If the rocker arms cannot be moved and the valves are slightly open, the No. 1 piston is on the exhaust stroke. Refer to Crankshaft Position For Fuel Timing And Valve Lash Setting.

   Note: If the actual stroke position that is identified is incorrect and the other stroke position is needed, remove all timing pins from the engine. After all of the timing pins have been removed, rotate the flywheel for 360 degrees in the direction of normal rotation.

Crankshaft Positions for Fuel Injector Adjustment and Valve Lash Setting

Illustration 46	g01268625
3606 cylinder and valve location (A) Inlet (B) Exhaust

Table 9

Crankshaft Positions for Fuel Injector Timing and Valve Lash Setting
3606 Engine	Check And Adjust With No. 1 Piston On The Following Stroke: (1)
	Top Center Compression Stroke	Top Center Exhaust Stroke
SAE Standard Rotation Engines (2)
Inlet Valves	1-2-4	3-5-6
Exhaust Valves	1-3-5	2-4-6
Fuel Injectors	3-5-6	1-2-4
Firing Order	1-5-3-6-2-4
SAE Opposite Rotation Engines (3)
Inlet Valves	1-3-5	2-4-6
Exhaust Valves	1-2-4	3-5-6
Fuel Injectors	2-4-6	1-3-5
Firing Order	1-4-2-6-3-5

( 1 )	Put the No. 1 piston at the top center position and identify the correct stroke. Refer to ""Finding the Top Center Position for the No. 1 Piston" ". After the top center position for a particular stroke is found and the adjustments are made for the correct cylinders, remove the timing pin. Turn the flywheel for 360 degrees in the direction of normal engine rotation. Turning the flywheel 360 degrees will put the No. 1 piston at the top center position on the other stroke. Install the timing pin in the crankshaft and complete the adjustments for the cylinders that remain.
( 2 )	SAE Standard Rotation Engines turn in the counterclockwise direction when the engines are viewed from the flywheel end.
( 3 )	SAE Opposite Rotation Engines turn in the clockwise direction when the engines are viewed from the flywheel end.

Illustration 47	g01268552
3608 cylinder and valve location (A) Inlet (B) Exhaust

Table 10

Crankshaft Positions for Fuel Injector and Valve Lash Setting
3608 Engine	Check and Adjust with No. 1 Piston on the Following Stroke: (1)
	Top Center Compression Stroke	Top Center Exhaust Stroke
SAE Standard Rotation Engines (2)
Inlet Valves	1-4-6-7	2-3-5-8
Exhaust Valves	1-2-4-6	3-5-7-8
Fuel Injectors	2-3-5-8	1-4-6-7
Firing Order	1-6-2-5-8-3-7-4
SAE Opposite Rotation Engines (3)
Inlet Valves	1-2-4-6	3-5-7-8
Exhaust Valves	1-4-6-7	2-3-5-8
Fuel Injectors	3-5-7-8	1-2-4-6
Firing Order	1-4-7-3-8-5-2-6

( 1 )	Put the No. 1 piston at the top center position and identify the correct stroke. Refer to Testing and Adjusting, "Finding the Top Center Position for the No. 1 Piston". After the top center position for a particular stroke is found and the adjustments are made for the correct cylinders, remove the timing pin. Turn the flywheel for 360 degrees in the direction of normal engine rotation. Turning the flywheel 360 degrees will put the No. 1 piston at the top center position on the other stroke. Install the timing pin in the crankshaft and complete the adjustments for the cylinders that remain.
( 2 )	SAE Standard Rotation Engines turn in the counterclockwise direction when the engines are viewed from the flywheel end.
( 3 )	SAE Opposite Rotation Engines turn in the clockwise direction when the engines are viewed from the flywheel end.

Illustration 48	g01296450
3612 Cylinder And valve location (A) Inlet (B) Exhaust (C) Flywheel

Table 11

Crankshaft Positions for Fuel Injector and Valve Lash Adjustment
3612 Engine	Check And Adjust With No. 1 Piston On The Following Stroke: (1)
	Top Center Compression Stroke	Top Center Exhaust Stroke
SAE Standard Rotation Engines (2)
Inlet Valves	1-3-6-7-10-12	2-4-5-8-9-11
Exhaust Valves	1-4-5-6-9-12	2-3-7-8-10-11
Fuel Injectors	2-4-5-8-9-11	1-3-6-7-10-12
Firing Order	1-12-9-4-5-8-11-2-3-10-7-6
SAE Opposite Rotation Engines (3)
Inlet Valves	1-4-5-6-9-12	2-3-7-8-10-11
Exhaust Valves	1-3-6-7-10-12	2-4-5-8-9-11
Fuel Injectors	2-3-7-8-10-11	1-4-5-6-9-12
Firing Order	1-6-7-10-3-2-11-8-5-4-9-12

( 1 )	Put the No. 1 piston at the top center position and identify the correct stroke. Refer to ""Finding the Top Center Position for the No. 1 Piston" ". After the top center position for a particular stroke is found and the adjustments are made for the correct cylinders, remove the timing pin. Turn the flywheel for 360 degrees in the direction of normal engine rotation. Turning the flywheel 360 degrees will put the No. 1 piston at the top center position on the other stroke. Install the timing pin in the crankshaft and complete the adjustments for the cylinders that remain.
( 2 )	SAE Standard Rotation Engines turn in the counterclockwise direction when the engines are viewed from the flywheel end.
( 3 )	SAE Opposite Rotation Engines turn in the clockwise direction when the engines are viewed from the flywheel end.

Illustration 49	g01296453
3616 Cylinder And valve location (A) Inlet (B) Exhaust (C) Flywheel

Table 12

Crankshaft Positions For Fuel Timing And Valve Lash Adjustment
3616 Engine	Check And Adjust With No. 1 Piston On The Following Stroke: (1)
	Top Center Compression Stroke	Top Center Exhaust Stroke
SAE Standard Rotation Engines (2)
Inlet Valves	1-2-5-7-8-12-13-14	3-4-6-9-10-11-15-16
Exhaust Valves	1-2-3-4-5-6-7-8	9-10-11-12-13-14-15-16
Fuel Injectors	3-4-6-9-10-11-15-16	1-2-5-7-8-12-13-14
Firing Order	1-2-5-6-3-4-9-10-15-16-11-12-13-14-7-8
SAE Opposite Rotation Engines (3)
Inlet Valves	1-2-3-4-5-6-7-8	9-10-11-12-13-14-15-16
Exhaust Valves	1-2-5-7-8-12-13-14	3-4-6-9-10-11-15-16
Fuel Injectors	9-10-11-12-13-14-15-16	1-2-3-4-5-6-7-8
Firing Order	1-8-7-14-13-12-11-16-15-10-9-4-3-6-5-2

( 1 )	Put the No. 1 piston at the top center position and identify the correct stroke. Refer to ""Finding the Top Center Position for the No. 1 Piston" ". After the top center position for a particular stroke is found and the adjustments are made for the correct cylinders, remove the timing pin. Turn the flywheel for 360 degrees in the direction of normal engine rotation. Turning the flywheel 360 degrees will put the No. 1 piston at the top center position on the other stroke. Install the timing pin in the crankshaft and complete the adjustments for the cylinders that remain.
( 2 )	SAE Standard Rotation Engines turn in the counterclockwise direction when the engines are viewed from the flywheel end.
( 3 )	SAE Opposite Rotation Engines turn in the clockwise direction when the engines are viewed from the flywheel end.

Valve Bridge Adjustment

When the cylinder head is disassembled, keep the bridges and the respective valves together. To adjust the bridges, use the procedure that follows:

Note: The bridges can be adjusted without removal of the rocker arms and shafts. Fully close the valves when the adjustment is made. Refer to ""Finding the Top Center Position for the No. 1 Piston" ". Also refer to ""Crankshaft Positions for Fuel Injector Adjustment and Valve Lash Setting" ". These references contain information regarding the valve position.

Illustration 50	g01268722
Bridge Installation (1) Top contact surface (2) Locknut (3) Bridge

Illustration 51	g00565733
Bridge Adjustment (2) Locknut (3) Bridge (4) Adjustment screw (5) Bridge dowel

1. Lubricate bridge dowel (5) in the cylinder head and the bore in bridge (3) with 8T-2998 Lubricant .

2. Install bridge (3). The adjustment screw (4) should be positioned toward the exhaust manifold.

3. Loosen locknut (2) and adjustment screw (4) for several turns.

4. Put a force of 50 ± 10 N (11 ± 2 lb) by hand straight down on top contact surface (1) of bridge (3) .

5. Turn adjustment screw (4) clockwise, until the adjustment screw contacts the valve stem. Turn the adjustment screw clockwise for another 45 degrees in order to make bridge (3) straight on the bridge dowel (5). Also, this additional rotation compensates for the clearance in the threads of the adjustment screw.

6. Hold adjustment screw (4) in this position and tighten locknut (2) to a torque of 100 ± 15 N·m (75 ± 11 lb ft).

7. Put clean engine oil on top contact surface (1) at the contact point between the rocker arm and bridge (3) .

Valve Lash Adjustment

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NOTICE
The procedures for engine valve lash should be performed according to the information in the Service Manual. Operation of Caterpillar engines with improper valve adjustments will reduce engine efficiency. This reduced efficiency could result in excessive fuel usage and/or shortened engine component life.

Table 13

Setting The Valve Lash (1)
Valves	Dimension Of The Feeler Gauge
Inlet	0.60 mm (.024 inch)
Exhaust	1.0 mm (.039 inch)

( 1 )

The valve lash should only be adjusted while the engine is stopped.

1. Rotate the No. 1 piston to the Top Center position. Refer to ""Finding the Top Center Position for the No. 1 Piston" ". With the No. 1 piston at the Top Center position of the compression stroke, adjust the valves. Refer to ""Crankshaft Positions for Fuel Injector Adjustment and Valve Lash Setting" ".

2. Ensure that the valve bridges are adjusted. Refer to ""Valve Bridge Adjustment" ".

3. Insert the 6V-3075 Dial Indicator from the timing group into the 4C-6593 Adjustment Tool . Tighten the retaining screw finger tight.

   Note: Make sure that the 6V-3075 Dial Indicator is used with the short contact point.

4. Use the threaded hole that is nearest to the end of the rocker arm that will be adjusted for the adjustment tool. Position the dial indicator stem over the flat area on the end of the rocker arm. Tighten the knob. Rotate the dial indicator so that the dial indicator can be easily read. Make sure that the adjustment tool is rigid and that the dial indicator stem moves freely.

5. Loosen the locknut on the rocker arm adjustment screw and turn the rocker arm adjustment screw clockwise until there is no valve lash. Loosen slightly. The valve lash should be zero. The valves should not be open any amount.

6. Set the dial indicator to zero.

7. Lift firmly on the valve end of the rocker arm and turn the rocker arm adjustment screw until the dial indicator shows 0.60 mm (.024 inch) for the inlet valves, and 1.00 mm (.039 inch) for the exhaust valves.

8. Try to move the rocker arm while you are lifting on the rocker arm. The dial indicator reading will vary. Read the dial indicator when the rocker arm is positioned in the groove of normal operation.

9. Tighten the locknut on the adjustment screw to a torque of 200 ± 25 N·m (150 ± 18 lb ft).

10. Recheck the valve lash setting in order to ensure that the valve lash is correct. Reset, as required.

11. After completing all of the valve lash checks and the valve lash adjustments for this crankshaft position, remove the timing pin from the crankshaft. Rotate the crankshaft to the next position. Install the timing pin in the crankshaft. Repeat Steps 2 through 10.

12. Remove the timing pin from the crankshaft when all valve lash adjustments have been completed.

Fuel Injector Adjustment

Table 14

Tools Needed	Quantity
4C-6594 Timing and Fuel Setting Tool	1
6V-3075 Dial Indicator	1
6V-9058 Fixture As	1
8S-3675 Indicator Contact Point	1
6V-9056 Setting Gauge	1

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The Electronic Control Module produces high voltage. To prevent personal injury make sure the Electronic Control Module is not powered and the unit injector solenoids are disconnected.

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NOTICE
The camshafts must be correctly timed with the crankshaft before an adjustment of the unit injector lash is made. The timing pins must be removed from the camshafts before the crankshaft is turned or damage to the cylinder block will be the result.

Note: The fuel injector adjustment is critical. Ensure that the adjustment of the fuel injector is made properly.

1. Refer to ""Crankshaft Positions for Fuel Injector Adjustment and Valve Lash Setting" ". All of the injectors can be checked or adjusted with the two crankshaft positions in the chart. Ensure that the pushrod lifters are off the lobes and on the base circles of the camshaft.

   Before a check or an adjustment can be made, the tooling must be set to the correct dimension. Use the following procedure in order to set the tooling to the correct dimension:

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   Illustration 52	g00359732
   Adjustment Of Fuel Timing Tools (1) 6V-3075 Dial Indicator (2) 6V-9058 Fixture Assembly (3) 6V-9056 Setting gauge (4) 8S-3675 Indicator Contact Point

   1. Install 8S-3675 Indicator Contact Point (4) on the 6V-3075 Dial Indicator (1) .

   2. Install 6V-3075 Dial Indicator (1) in the collet of 6V-9058 Fixture Assembly (2) .

   3. Install 6V-3075 Dial Indicator (1) with 6V-9058 Fixture Assembly (2) onto 6V-9056 Setting Gauge (3). Ensure that the magnetic base of the timing fixture is on the top surface and that the contact point is on the bottom step.

      Note: The 6V-3075 Dial Indicator (1) has two or three dials that register. The larger dial has marks for every 0.01 mm (0.0004 inch). The red numbers on the dial are for minus readings. The black numbers on the dial are for plus readings. The smaller dial has marks for 1.00 mm (0.040 inch) (one complete revolution of the large dial).

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Illustration 53	g01268685
(5) Retainer (6) Shoulder of the fuel injector

2. Ensure that the top surface of fuel injector retainer (5) and shoulder (6) must be clean and dry.

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Illustration 54	g01268731
Fuel timing tools in position Typical example (1) 6V-3075 Dial Indicator (2) 6V-9058 Fixture Assembly (7) Rocker arm adjustment screw (8) Rocker arm adjustment screw locknut

3. Put 6V-3075 Dial Indicator (1) that is installed in 6V-9058 Fixture Assembly (2) into position on the fuel injector. Ensure that the magnetic base of the timing fixture is on the top surface of the fuel injector retainer. The contact point must be on the top surface of shoulder (6) .

   Note: The pointer on both dials on the dial indicator must indicate 0.00 ± 0.20 mm (0.000 ± 0.008 inch).

4. If the dial indicator pointers are within the range of 0.00 ± 0.20 mm (0.000 ± 0.008 inch), no adjustment is necessary. Proceed to Step 10.

5. If the dial indicator pointers are not within the range of 0.00 ± 0.20 mm (0.000 ± 0.008 inch), complete Steps 6 through 10.

6. Loosen the rocker arm adjustment screw locknut (8) on the fuel injector that requires adjustment.

7. Put 6V-3075 Dial Indicator (1) that is installed in 6V-9058 Fixture Assembly (2) into position on the fuel injector. Ensure that the magnetic base of the timing fixture is on the top surface of the fuel injector retainer. The contact point must be on the top surface of shoulder (6) .

8. Turn rocker arm adjustment screw (7) until the dial indicator indicates "0".

   A setting of "0" means that the height of the spring has been set to 118.2 mm (4.6535 inch).

9. Tighten rocker arm adjustment screw locknut (8) to a torque of 200 ± 25 N·m (150 ± 18 lb ft), and check the adjustment again. If necessary, do this procedure until the adjustment is correct.

10. Remove the timing pin from the crankshaft when the fuel injector adjustment check is completed.

Engine Wiring System

The engine wiring system will connect the following components.

• Primary Electronic Control Module (ECM)

• Backup ECM

• Rigid rail

• Customer Interface Panel (CIP)

1. Remove the 157-5187 Control Panel Gp .

   The control panel will not be reused.

2. Remove the 147-2968 Pressure Sensor Gp .

   This sensor is the atmospheric pressure sensor.

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   Illustration 55	g01268592
   In-line engine sensor location (1) 147-2968 Pressure Sensor Gp

   1. For in-line engines, sensor (1) is located on the exhaust manifold.
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   Illustration 56	g01268710
   Vee engine sensor location (1) 147-2968 Pressure Sensor Gp

   2. For vee engines, sensor (1) is located on the aftercooler.

Rigid Rail

Illustration 57	g01278900
Typical example

The rigid rail provides a protected, serviceable conduit for the following engine wiring harnesses.

• Inlet manifold air pressure sensor

• Primary speed timing sensor

• Secondary speed timing sensor

• Fuel injector solenoids

Install the Rigid Rail

Table 15

Required Parts
Sales Model	Part Number	Description
3606	273-4807	Engine Wiring Gp
3608	273-4808	Engine Wiring Gp
3612	273-4769	Engine Wiring Gp
3616	273-4770	Engine Wiring Gp

1. Install the rigid rail.

   The rigid rail on 3606 engines is mounted to the engine in three places. The rigid rail on 3608 engines is mounted to the engine in four places. The rigid rail for 3612 engines is mounted to the engine in six places. The rigid rail for 3616 engines is mounted to the engine in eight places.

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   Table 16

   Part Numbers for the Rigid Rail
   Sales Model	Part Number
   3606	273-4803
   3608	273-4802
   3612	273-4773 (Right side) 273-4774 (Left side)
   3616	273-4814 (Right side) 273-4815 (Left side)

2. Install the wiring group onto the engine.

   Refer to the prints in Table 15 for more information on installing the wiring group.

3. Replace the thermocouples on the engine with the 283-6459 Temperature Sensor Gp .

   Refer to the prints in Table 15 for more information on installing the thermocouples.

4. Connect all of the harnesses for the fuel injectors to the fuel injectors.

Primary ECM

The main function of the primary ECM is to control fuel delivery and engine timing. The primary ECM also provided the following functions.

• Diagnostic and event information

• Sensor parameters

• Messenger communications

• Smoke control

• Load feedback

• Fuel usage data

Secondary ECM

The secondary ECM provides a means to operate the engine if the primary ECM fails. The secondary ECM monitors the Cat Data Link and the primary ecm heartbeat signal. The secondary ECM also provides a backup for the Marine Monitoring System (MMS) and/or the Marine Monitoring System II (MMSII) overspeed protection.

The secondary ECM does not support the following functions.

• Messenger communications

• Smoke control

• Timing control

• Load feedback

Install the ECM Mount and the ECMs for In-line Engines

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Illustration 58	g01268739
(1) 273-4776 Bracket As (2) 273-4775 Bracket As (3) 285-4386 Cover As (4) Primary ECM (5) Secondary ECM (6) 236-7534 Pressure Sensor Gp (7) 309-0869 Engine Harness As (8) 132-5789 Clip (9) 4P-7581 Clip

1. Assemble the 273-4777 Engine Electronic Control and Mounting Gp .

   1. Install ECMs (4) and (5) onto bracket (1) using 8T-9655 Isolation Mounts , 6I-1418 Spacers , 9N-0869 Hard Washers , and 7X-0818 Bolts .

   2. Use 5P-4116 Hard Washers and 8T-4908 Bolts to install bracket (2) .

   3. Use 5P-4116 Hard Washers and 8T-4189 Bolts to install cover (3) .

   4. Install harness (7). Use 7K-1181 Cable Straps and clips (8) and (9) to secure the harness.

   5. Use 7K-1181 Cable Straps to install sensor (6) .

   6. Install the bulkhead connector for the rigid rail.

   7. Install the bulkhead connector for the Marine Monitoring System (MMS).

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Illustration 59	g01268692
Typical example (10) Center line (11) 273-4778 Access Cover As

2. Install the 273-4779 Engine Electronic Control and Mounting Gp onto the right side of the engine.

   For 3606 engines, centerline (10) is the centerline for the number five cylinder. For 3608 engines, centerline (10) is the centerline for the number seven cylinder.

   1. Use 5P-1075 Hard Washers and 5S-7383 Bolts to install bracket (1) onto the engine.

   2. Use 5P-1075 Hard Washers and 7X-0288 Bolts to install bracket (2) onto the engine.

   3. Connect harness (7) to the wiring harness for the rigid rail.

   4. Ensure that all electrical connections are properly secured.

   5. Use 5P-4116 Hard Washers and 8T-4189 Bolts to install cover (11) .

Install the ECM Mount and the ECMs for Vee Engines

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Illustration 60	g01268669
(4) Primary ECM (5) Secondary ECM (6) 236-7534 Pressure Sensor Gp (7) 309-0870 Engine Harness As (8) 132-5789 Clip (12) 273-4726 Mounting Bracket As

1. Assemble the 273-4730 Engine Electronic Control and Mounting Gp .

   1. Install the ECMs (4) and (5) onto bracket (12) using 8T-9655 Isolation Mounts , 6I-1418 Spacers , 9N-0869 Hard Washers , and 7X-0818 Bolts .

   2. Install harness (7). Use 7K-1181 Cable Straps and clips (8) to secure the harness.

2. Install the primary and the secondary ECMs on the 273-4730 Engine Electronic Control and Mounting Gp .

3. Connect all wiring harness connections.

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Illustration 61	g01268725

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Illustration 62	g01268635
Flywheel side of the engine (13) 9X-8887 Bolt (14) 0S-1591 Bolt (15) 8T-2502 Bolt (16) 1A-2029 Bolt

4. Install the 273-4728 Support .

   1. Install bolts (13) in location (A) with 5P-8248 Hard Washers .

   2. Install bolts (14) in location (B) with 5M-2894 Hard Washers .

5. Install the 273-4730 Engine Electronic Control and Mounting Gp .

   1. Install bolts (15) in location (C) with 8T-4121 Hard Washers .

   2. Install sensor (6) at location (E) .

   3. Install the bulkhead connectors for the rigid rail.

   4. Install the bulkhead connectors for the MMS.

6. Install the 273-4727 Cover onto the 273-4728 Support .

   Install bolts (16) in location (D) with 5M-2894 Hard Washers .

235-5200 Instrument Mounting Group for Marine Propulsion

Illustration 63	g01268572
Typical example of the 235-5195 Instrument Panel Gp (17) Messenger (18) Speed control (19) Speed control potentiometer (20) Local/Remote Switch (21) General alarm relay or shutdown notify relay (22) General alarm relay or shutdown notify relay (23) Secondary ECM ready lamp (24) Secondary ECM active lamp (25) Diagnostic primary lamp (26) Diagnostic secondary lamp (27) Isolator for load feedback (28) Breaker for main power 20A (29) Breaker for primary ECM 10A (30) Breaker for secondary ECM 10A (31) Breaker for other loads 10A (32) Isolator for secondary throttle (33) Isolator for primary throttle

Note: The instrument panel can be mounted remotely.

1. Install the 235-5200 Instrument Mounting Group in a suitable location.

   Mount the 235-5200 Instrument Mounting Group close to the MMS and the Engine Control Panel (ECP). Mounting close to the MMS and ECP will minimize the length of wiring that is needed to connect the two panels. Refer to the Electrical Schematic for the engine to aid in connecting the two panels.

2. On in-line engines, install the 235-5147 Engine Harness As from the 273-4777 Engine Electronic Control and Mounting Gp to the 235-5195 Instrument Panel Gp .

3. On vee engines, install the 235-5147 Engine Harness As from the 237-4730 Engine Electronic Control and Mounting Gp to the 235-5195 Instrument Panel Gp .

Customer Connector

Illustration 64	g01268720

Table 17

Customer Connector
Pin Number	Function	Description	Pin Number	Function	Description
1	Positive battery	+ 24 VDC	21	Shut down notification relay (NC)	Opens when engine is running. Provides + 24 VDC when closed
2	Negative battery	24V Return	22	General alarm relay (NC)	Opens when engine diagnostics occur. Provides + 24 VDC when closed.
3	Negative battery	24V Return	23	Back up diagnostic lamp	Used for remote mounting of lamp. A + 24 VDC sinking driver
4	Unused		24	Primary diagnostic lamp	Used for remote mounting of lamp. A + 24 VDC sinking driver
5	Positive battery	+ 24 VDC	25	Load feedback signal negative	The return for the 4-20mA load feedback signal
6	CAT Data Link negative	Data Link twisted pair with pin 7	26	Load feedback signal positive	The source for the 4-20mA load feedback signal
7	CAT Data Link positive	Data Link twisted pair with pin 6	27	Backup ECM active	Used for remote mounting of lamp. A + 24 VDC sinking driver
8	Positive battery	+ 24 VDC	28	Backup ECM ready	Used for remote mounting of lamp. A + 24 VDC sinking driver
9	Negative battery	24V Return	29	Global throttle PWM	Used as second throttle control source
10	Remote throttle position (PWM)	PWM signal	30	Key switch input	+ 24 VDC is required to enable the governor control
11	Air shutoff signal	+ 24 VDC when enabled	31	Local/remote throttle selection	Floating input = remote Digital ground = local
12	Air shutoff driver return	24V Return	32	Unused
13	General alarm relay (common)	+ 24 VDC	33	Local speed potentiometer 1	Used to mount the local speed potentiometer
14	Key switch output	+ 24 VDC to enable governor control	34	Local speed potentiometer 2	Used to mount the local speed potentiometer
15	General alarm relay (NO)	Closes when engine control diagnostics occur. Provides + 24 VDC when closed	35	Local speed potentiometer 3	Used to mount the local speed potentiometer
16	Shield for the CAN data link	Shield wire for CAN data link cable	36	Remote shutdown	Pull to digital return to activate. Deactivated when floating
17	CAN data link positive	CAN shielded twisted pair with pin 18	37	Global throttle selection	Used to toggle between local/remote throttle and the global throttle
18	CAN data link negative	CAN shielded twisted pair with pin 17	38	Multi dynamic select switch	Used to select between the variable gain map and the constant speed gain map
19	Shut down notification relay (common)	+ 24 VDC	39	Remote throttle position (4-20) negative	The return for the 4-20mA remote throttle signal
20	Shut down notification relay (NO)	Closes when engine is running. Provides + 24 VDC when closed.	40	Remote throttle position (4-20) positive	The input for the 4-20mA remote throttle signal

The customer connector is a 40 pin connector that is mounted on the bottom of the Customer Interface Panel (CIP). The customer connector provides the following.

• Power output

• Customer interface

• MMS/MMSII/ECP interface

289-0566 Instrument Mounting Group for Marine Auxiliary or Petroleum Engines

Illustration 65	g01351287
Typical example of the 289-0567 Instrument Panel Gp (17) Messenger (19) Speed control potentiometer (21) General alarm relay or shutdown notify relay (22) General alarm relay or shutdown notify relay (25) Diagnostic primary lamp (27) Isolator for load feedback (28) Breaker for main power 20A (29) Breaker for primary ECM 10A (31) Breaker for other loads 10A (34) Governor control

Note: The instrument panel can be mounted remotely.

1. Install the 289-0566 Instrument Mounting Group in a suitable location.

   Mount the 289-0566 Instrument Mounting Group close to the MMS/ECP. Mounting close to the MMS/ECP will minimize the length of wiring that is needed to connect the two panels. Refer to the Electrical Schematic for the engine to aid in connecting the two panels.

2. On in-line engines, install the 235-5147 Engine Harness As from the 273-4777 Engine Electronic Control and Mounting Gp to the 289-0567 Instrument Panel Gp .

3. On vee engines, install the 235-5147 Engine Harness As from the 237-4730 Engine Electronic Control and Mounting Gp to the 289-0567 Instrument Panel Gp .

Customer Connector

Illustration 66	g01268720

Table 18

Customer Connector
Pin Number	Function	Description	Pin Number	Function	Description
1	Positive battery	+ 24 VDC	21	Shut down notification relay (NC)	Opens when engine is running. Provides + 24 VDC when closed
2	Negative battery	24V Return	22	General alarm relay (NC)	Opens when engine diagnostics occur. Provides + 24 VDC when closed.
3	Negative battery	24V Return	23	Unused
4	Unused		24	Diagnostic lamp	Used for remote mounting of lamp. A + 24 VDC sinking driver
5	Positive battery	+ 24 VDC	25	Load feedback signal negative	The return for the 4-20mA load feedback signal
6	CAT Data Link negative	Data Link twisted pair with pin 7	26	Load feedback signal positive	The source for the 4-20mA load feedback signal
7	CAT Data Link positive	Data Link twisted pair with pin 6	27	Droop	PWM Signal
8	Positive battery	+ 24 VDC	28	Low idle input	Input taken to digital return for low idle
9	Negative battery	24V Return	29	Unused
10	Remote throttle position (PWM)	PWM signal	30	Key switch input	+ 24 VDC is required to enable the governor control
11	Air shutoff signal	+ 24 VDC when enabled	31	Unused
12	Air shutoff driver return	24V Return	32	Unused
13	General alarm relay (common)	+ 24 VDC	33	Local speed potentiometer 1	Used to mount the local speed potentiometer
14	Key switch output	+ 24 VDC to enable governor control	34	Local speed potentiometer 2	Used to mount the local speed potentiometer
15	General alarm relay (NO)	Closes when engine control diagnostics occur. Provides + 24 VDC when closed	35	Local speed potentiometer 3	Used to mount the local speed potentiometer
16	Shield for the CAN data link	Shield wire for CAN data link cable	36	Start/stop input	Taken to digital return to run, input floating to stop
17	CAN data link positive	CAN shielded twisted pair with pin 18	37	Unused
18	CAN data link negative	CAN shielded twisted pair with pin 17	38	Unused
19	Shut down notification relay (common)	+ 24 VDC	39	Direct rack +	Input for the 0 - 200mA direct rack signal
20	Shut down notification relay (NO)	Closes when engine is running. Provides + 24 VDC when closed.	40	Direct rack -	Return for the 0 - 200mA direct rack signal

The customer connector is a 40 pin connector that is mounted on the bottom of the Customer Interface Panel (CIP). The customer connector provides the following.

• Power output

• Customer interface

• MMS/MMSII/ECP interface

228-7424 Monitor Display Gp (Messenger)

Illustration 67	g01268561
Panel mounted display (1) 228-7424 Monitor Display Gp

The 228-7424 Monitor Display Gp connects to the CAN data link. The display on the unit shows the following menus.

• "System Parameters"

• "Totals Information"

• "Diagnostic Data"

• "Display Configuration"

Note: All wiring must meet local requirements. All wiring must be 16 gauge wire or larger.

Illustration 68	g01268717

The 228-7424 Monitor Display Gp can be remotely mounted up to 30.5 m (100 ft) from the 235-5195 Instrument Panel Gp .

Remote Mounting of the 228-7424 Monitor Display Gp

Illustration 69	g01268727

1. Construct a harness using 5P-5623 Electrical Wire and/or 5P-5677 Wire that is the desired length.

   Refer to Illustration 69 for the terminal information.

2. Mount the 228-7424 Monitor Display Gp in the desired location.

   The 227-4283 Mounting Bracket Gp is used when the display is mounted remotely.

Marine Monitoring System (MMS) and Marine Monitoring System II (MMSII)

Power Connections to the Customer Interface Panel (CIP)

Illustration 70	g01268714

Note: The power supplies for the MMS/MMSII/ECP and the EUI may be the same. If the power supplies for the MMS/MMSII/ECP and the EUI are different, the B negative must be grounded in the same location.

Illustration 71	g01268527
156-1460 Receptacle (1) 235-5200 Instrument Mounting Group (2) 156-1460 Receptacle

The power connection supplies power to the electronic fuel injector (EUI) system. Receptacle (3) connects to the 172-3998 Plug As . The wire size for the power connections must be at least 12 AWG.

Connections for the Air Shutoff to the CIP

Illustration 72	g01268743

Connections for the General Alarm

Illustration 73	g01351452

Connections for the Key Switch Input

Illustration 74	g01351453

Connections for the Shutdown Signal to the CIP

Illustration 75	g01268721

The shutdown signal connections allow the MMS/MMSII/ECP to shut down the engine. The engine is shut down by energizing the fuel control relay.

The relay will be de-energized when any of the following conditions are met.

• Overspeed verify that the feature has caused a shutdown.

• RPM is below 200 RPM.

• Shutdown input is active from the MMS/MMSII/ECP

Connections for the Shutdown Notification Output to the Customer Connection

Illustration 76	g01268737

The shutdown notify relay will be de-energized when any of the following conditions are met.

• Overspeed verify that the feature has caused a shutdown.

• RPM is below 200 RPM.

• Shutdown input is active from the MMS/MMSII/ECP

Load Feedback Signal Connections to the Customer Connector (Marine Propulsion Only)

Illustration 77	g01268583

The 283-9351 Sensor Harness As load feedback isolator provides a signal to the primary ECM. This signal is proportional to the percent of available power that the engine can produce. The signal from the isolator must be isolated. The load feedback isolator replaces the position indicator on the Heinzmann rack. Refer to the Troubleshooting manual for information on calibrating the load feedback isolator.

The load feedback isolator is installed in the CIP. Refer to Illustration 63.

Throttle Input Connections to the CIP

Illustration 78	g01268538
(3) 8D-2676 Toggle Switch (4) 9X-9591 Electrical Converter Gp (5) 127-9069 Potentiometer

The throttle input provides a throttle signal to the primary ECM and to the backup ECM. The throttle input also allows for local control of the engine speed.

EUI Wiring Check

Power the EUI system

1. Energize the breakers.

2. Ensure that the breakers remain energized.

Connect Caterpillar Electronic Technician (ET) to the CIP

Connecting Cat ET with the 171-4401 Communication Adapter II

The battery supplies the communication adapter with 24 VDC. Use the following procedure to connect Cat ET to the ECM.

1. Turn the engine control switch to the OFF/RESET position.

Show/hide table



Illustration 79	g01268726
(1) PC (2) 196-0055 Serial Cable or the 160-0141 Serial Cable (3) 171-4401 Communication Adapter II (4) 207-6845 Adapter Cable

2. Connect cable (2) to the RS-232 serial port of PC (1) .

3. Connect cable (2) to communication adapter (3) .

4. Connect cable (4) to communication adapter (3) .

5. Connect cable (4) to the service tool connector on the engine mounted CIP.

6. Turn the engine control switch to the LOCAL position or to the REMOTE position. Turn the fuel control switch to the FUEL OFF position. The engine should be OFF.

   If Cat ET and the communication adapter do not communicate with the ECM, refer to the engine Troubleshooting Manual.

Download the Flash File From SISWeb

1. Log onto SISWeb.

2. Click on the "Service Software Files" link that is located in lower right subject list.

3. Click on the "Flash Files" link that is located at the top of list In the "Flash File Name" box.

4. Enter the desired flash file part number.

5. Download the flash file at the right of the screen.

Troubleshooting

Refer to the engine Troubleshooting manual for more information on the following components.

• Sensor faults

• Injector faults

• Response checks for the throttle input

• Shutdown input response checks

Requirements for the Electrical System

When you route the wiring, avoid acute bends and sharp edges. To protect the wiring harnesses, route the harnesses through a metal conduit. Use a rigid conduit or a use flexible conduit. A liquid tight conduit is recommended. Use proper support and alignment in order to avoid strain on the conduit.

Electronic Service Tools

Caterpillar electronic service tools are designed to help the service technician perform the following tasks:

• Information access

• System diagnostics

• System calibrations

• System configurations

• Data link communications

Required Service Tools

The tools that are listed in Table 19 are required in order to enable a service technician to perform the electrical installation and the initial start-up.

Table 19

Required Service Tools
Part Number	Description
N/A	4 mm Allen Wrench
6V-2197	Transducer
7X-1171	Transducer Adapter
7X-1695	Cable As
146-4080	Digital Multimeter Gp (RS232)
7X-1710	Multimeter Probes
7X-6370	Adapter Cable As (3-PIN BREAKOUT)
208-0059	Adapter Cable As (70-PIN BREAKOUT)
257-8718	Adapter Cable As (120-PIN BREAKOUT)
167-9225	Harness (SERVICE TOOL ADAPTER)
1U-5804	Crimp Tool (12−AWG TO 18−AWG)
175-3700	Connector Repair Kit (deutsch connector DT)

Two short jumper wires are needed to check the continuity of some wiring harness circuits by shorting two adjacent terminals together in a connector. A long extension wire may also be needed to check the continuity of some wiring harness circuits.

Optional Service Tools

Table 20 lists the optional service tools that may be needed during testing or repair.

Table 20

Optional Service Tools
Part Number	Description
198-4240 or 1U-5470	Digital Pressure Indicator Engine Pressure Group
4C-4075	Crimp Tool (4−AWG TO 10−AWG)
4C-4911 (1)	Battery Load Tester
5P-7277	Voltage Tester
6V-9130 (2)	Temperature Adapter (MULTIMETER)
8T-5319	Connector Tool Group
155-5176	AC/DC Current Probe

( 1 )	Refer to Special Instructions, SEHS9249, "Use of 4C-4911 Battery Load Tester for 6, 8, and 12 V Lead Acid Batteries" and Special Instructions, SEHS7633, "Battery Test Procedure".
( 2 )	Refer to Special Instructions, SEHS8382, "Use of the 6V-9130 Temperature Adapter Group".

Cat ET

Cat ET can display the following information:

• Parameters

• Event codes

• Diagnostic codes

• Engine configuration

Cat ET can be used by the technician to perform the following functions:

• Diagnostic tests

• Calibrations

• Flash programming

• Configuration of the Electronic Control Module (ECM)

Table 21 lists the software that is required in order to use Cat ET. Always use the latest version of Cat ET that is available.

Table 21

Software Requirements for Cat ET
Part Number	Description
JERD2124	Single user license for Cat ET
JERD2129	Data subscription for all engines and machines

Note: For more information regarding the use of Cat ET, refer to the documentation that accompanies your Cat ET software.

Connecting Cat ET with the Communication Adapter II

Table 22 lists the standard hardware that is required in order to connect Cat ET.

Table 22

Standard Hardware for the Use of Cat ET
Part Number	Description
N/A	Personal Computer (PC)
275-5120 (1)	Communication Adapter Gp (CAT ET TO ECM INTERFACE)
237-7547 (2)	Adapter Cable As
225-5985 (3)	Parallel Port Cable (COMMUNICATION ADAPTER)

( 1 )	The 7X-1700 Communication Adapter Gp may also be used.
( 2 )	The 237-7547 Adapter Cable As is required to connect to the Universal Serial Bus (USB). The adapter is to be used on computers that are not equipped with an RS232 serial port.
( 3 )	The 225-5985 Parallel Port Cable is required to connect to the parallel port.

Illustration 80	g01255306
Connecting the Communication Adapter II (1) Personal Computer (PC) (2) 237-7547 Adapter Cable As (3) 196-0055 Adapter Cable As (4) 225-5985 Parallel Port Cable (COMMUNICATION ADAPTER) (5) 275-5121 Communication Adapter As (6) 207-6845 Adapter Cable As

Note: Items (3), (5), and (6) are part of the 275-5120 Communication Adapter Gp .

Use the following procedure in order to connect Cat ET and the Communication Adapter II.

1. Remove the electrical power from the ECM.

2. Connect communications adapter (5) to a communications port on the PC by using one of the following methods:

   1. Connect cable (4) between the "COMPUTER" end of communications adapter (5) and the parallel port of PC (1). Be sure to configure Cat ET for the parallel port. This configuration provides the fastest connection.

   2. Connect cable (3) between the "COMPUTER" end of communication adapter (5) and the RS232 serial port of PC (1) .

   3. Connect cables (2) and (3) between the "COMPUTER" end of communication adapter (5) and the USB port of PC (1) .

3. Connect cable (6) to communication adapter (5) .

4. Connect cable (6) to a service tool connector.

5. Verify that the "POWER" indicator on the communication adapter is illuminated.

6. Establish communication between Cat ET and the ECM.

7. If Cat ET and the communication adapter do not communicate with the ECM, refer to troubleshooting without a diagnostic code Troubleshooting, "Electronic Service Tool Will Not Communicate with ECM".

Communicating with the Wireless Communication Adapter

Table 23 lists the optional hardware that is needed in order to connect Cat ET by using a wireless connection.

Table 23

Optional Hardware for the Use of Cat ET
Part Number	Description
N/A	Personal Computer (PC)
261-3363 (1)	Wireless Communication Adapter Gp

( 1 )

Refer to Tool Operating Manual, "Using the 261-3363 Wireless Communication Adapter Gp " for information that is related to the installation and the configuration.

Illustration 81	g01297379
(1) Personal computer (PC) (7) 261-4867 Card (PCMCIA) (8) 239-9955 Communication Radio Gp (9) 259-3183 Data Link Cable As

Note: Items (7), (8), and (9) are part of the 261-3363 Wireless Communication Adapter Gp .

Use the following procedure in order to connect the wireless communication adapter for use with Cat ET.

1. Remove the electrical power from the ECM.

2. Ensure that the computer has been correctly configured for the 261-4867 Card (PCMCIA). Verify that the PC card is installed in the computer PCI expansion slot.

3. Connect cable (9) between communication radio (8) and the service tool connector.

4. Restore the electrical power to the ECM. If Cat ET and the communication radio do not communicate with the ECM, refer to troubleshooting without a diagnostic code Troubleshooting, "Electronic Service Tool Will Not Communicate with ECM".

Starting System

The EUI system requires that the crankshaft rotate at a minimum of 70 rpm. The engine starting system must be able to supply the air pressure and flow to the starting motor in order to start the engine. The vane type starting motors may be replaced with turbine type starting motors.

If the existing starting system does not meet the 70 rpm requirement, the starting motors must be replaced with turbine type starting motors. Refer to Table 24 for a list of part numbers for the recommended turbine type starting motors for 3600 Engines. For a dual starting motor application, two of the motor group part number must be ordered.

Air lines to the starting motors must be modified for the turbine starters. A lubricating device is not required for the turbine type starting motors. Any lubricating device must be removed. The air lines for a single starting motor must have a minimum diameter of 38.1 mm (1.5 inch). Air lines for dual starting motors must have a minimum diameter of 76.2 mm (3.0 inch).

Table 24

Turbine Type Starting Motors for 3600 Engine Applications
Sales Model	Standard Rotation	Reverse Rotation	Quantity
3606 and 3608	269-3839	275-8518	1
3612 (1)	295-6006	295-6007
	246-1241	246-4483	2
3616

( 1 )

3612 Engines can be started by dual starting motors or by a single starting motor. A single starting motor may only be used in cases when minimal parasitic torque is coupled to the engine during cranking. Dual starters may be required in applications when a 3612 Engine must be started in cold ambient conditions. Cold ambient condition will raise the viscosity of the engine oil. Cold conditions increase the cranking torque that is required in order to crank the engine at the 70 rpm requirement. The part number for a single starting motor is different than the part number for the dual starting motors. One of the dual starting motors does not provide the torque that is required in order to start the engine.

Start-up Procedure

Refer to the Operation and Maintenance, "Starting the Engine". Verify that the throttle control switch is in the LOCAL position.

Verify that the fuel pressure for the engine is set correctly. The fuel pressure must be 820 ± 20 kPa (120 ± 3 psi). Measure the fuel pressure by using the MMS or by using a mechanical fuel pressure gauge (if equipped).

Verify that the Fuel Injectors are Operating Properly

Perform an injector solenoid test using Cat ET. Verify that each of the injectors is operating properly.

Verify that the Messenger Display is Operating Properly

1. Verify that the display is operating properly.

2. Verify that the data screens are functioning properly.

Transfer Control to the Remote Speed Control

1. Ensure that the remote throttle is in the IDLE position.

2. Ensure that the local throttle is in the IDLE position.

3. Switch the remote/local throttle control switch to the REMOTE position. Refer to (20) in Illustration 63 that is located in "" 235-5200 Instrument Mounting Group " ".

Control the Engine Speed by Using the Remote Speed Control

Verify that the engine operates properly using the remote speed control.

Ensure that the Electrical System is Operating Properly

Disable Sensors

Unplug each sensor. Verify that Cat ET shows the fault for each sensor.

Disable the Primary ECM

Switch the breaker for the primary ECM to the OFF position. Refer to Illustration 63 for the location of the breaker. Verify that the secondary ECM active lamp of the CIP is illuminated.

Check for the Proper Operation of the Shutdown Notify

Verify that the shutdown notify relay is energized when the engine is running.

Check for the Proper Operation of the Load Output (Marine Propulsion Only)

Use Cat ET to calibrate the load output isolator. Refer to the Troubleshooting manual for more information.